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Discussion Starter · #1 ·
I have been at war with my valve cover leak for so long now. I have done rtv gray kind, rubber gasket and rtv, rubber gasket by itself, new valve cover plastic. I have read all the forums and only thing I see left to do is after market items. Does anyone have a good link to to a good fool proof gasket and/or any advice.

Seems to leak from the back and with just the rubber gasket it pours,,, rtv it drips, rtv and gasket it drips.

I'm done with this vc I done replace a stater before because it was leaking on it. I need a fix.
 

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Is it the crappy ABS plastic cover? Mine has also always leaked like a bastard. My 3rd gasket combo with no luck either.
 

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Its the valve cover. The plastic valve cover warps when it gets warm, and there isn't any way to prevent it. A new cover(plastic) is only good for about a year then it will do the same thing.

The way to prevent, is to drop the dime on an aluminum cover. A good quality fel-pro rubber gasket (the one with the aluminum inserts to prevent crushing in the bolt holes) and a thin coat of RTV between the cover and the gasket.

You can try it with the plastic cover. As long as no visible warping, clean it down really well around the gasket mounting area, apply a thing coat of RTV sealant, put the fel pro gasket on it, and let it dry completely (24hrs) then install it on the motor. clean the top of the head (gasket mounting surface) and install( no RTV). A star washer on the bolt helps to eliminate the bolts coming loose. Torque evenly in a cross pattern, 7-10lbs.
 

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^ I agree with 0III0. But I'll add, start from the center of the VC and work out in a cross pattern. You could also torque it twice. 1st time to about 3-4 lb ft (36-48 in lb), second time to 7 lb ft. It may work for you. Face it, it is a Jeep. If the VC doesn't leak, something else will!
 

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Check your PCV system they some times get full of crap at the Carb. {any where in it for that} and not work and cause High pressure inside the crank case and valve cover.
 

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You will hear over and over to switch to aluminum, getting away from the plastic. I was always skeptical until I recently made the switch. I would recomend this. I purchased a kit off ebay with an aluminum valve cover and all the hardware needed. If you have moderate wrenching skills you can do the conversion. In my case the holes were pre drilled from the factory and simply needed to be tapped making new threads. Took me a few hours and I had the new cover on and everything back together.

So far its been a month and a few hundred miles and no more leaks down the back of the engine dripping from the trans housing.

The kit I bought was
Jeep 1981 86 4 2L 6 Cyl Black Aluminum Valve Cover | eBay

I am sure there are better kits, but the seller was local to me and the price worked for me also.
 

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I would also recommend trying Permatex Rightstuff gasket sealer. I think it beats RTV hands down.
 

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Discussion Starter · #8 ·
I can't seem to find an aluminum valve cover for 89 2.5 there are tons of options for 6 cylinder
 

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Everyone claims they have them for the 2.5. I've NEVER seen then. I looked for a long time. I heard some older Chrysler covers would work. But I couldn't confirm it. I just assumed I was stuck with this crappy abs one.
 

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Yeah. Do you know what brand? All I've seen are for the 6.
 

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Discussion Starter · #14 ·
Still no go finally took to a local mechanic and they said same thing I was thinking to much blow by and it keeps blowing the seal, so now I'm left with rebuilding it or upgrading the engine to a six found on on a site that has 90k and good condition about the same price for a rebuild or to buy the parts jeep so what ya think guys,,


Rebuild it about 1k I can do myself

Or

Buy parts jeep1k has a six mine currently is 4 plus the jeep has a lot of parts I could use over time.


If you say the jeep anything I should know before the swap besides moving the motor mounts it is a 93 and mine is a 89 it is auto mine is manual.

Tks in advance for any advice.
 

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Well when my 2.5 4 banger dies... definately going with a 6cyl... If you got a parts jeep that means you have the upgraded transmission and transfercase ect ect ect, and a 6cyl to boot... I say parts Jeep.
 

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I say get a donor and transplant.
Only draw-back is you are getting used parts and don't know how much life is left.
So since you are going to be pulling from the donor, replace, repair, rebuild before transplant. It will be more expensive but worth it in the long run.
 

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Discussion Starter · #17 ·
Will I not be able I use my current setup I'd like to keep my manual I dislike auto but don't hate them.
 

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Discussion Starter · #18 ·
The motor is from a 99 the body was a 93 I'll do some research but anyone know off the top of there head how much that will affect dropping into a 89
 

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I recommend changing as many things as you can also before you drop in donor also. Last thing you need is to tear down after reinstall. Much easier when out.
 

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You Can Not use your manual AX5 behind the 4.0 it will tear up fast.
 
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